An integrated model for manufacturing process improvement

In order to survive in a competitive market, improving quality and profitability of products seem to be the only way. Some simple techniques like Statistical Process Control (SPC) and the seven basic tools are valuable and effective for this objective. Simple as they are, their benefits in process improvement have not been fully realized due to the lacking of an integrated approach. This paper presents a case study in which a local Printed Circuit Board (PCB) fabrication company employs very simple techniques (e.g. SPC and seven basic tools etc.) to significantly improve both product and process quality and productivity. At the same time, it verified the intimate relationship between SPC, the seven basic tools, KAIZEN and Total Quality Management (TQM) principles, which should be integrated in practice. Statistical Process Control (SPC) was proved to be an effective means to improve quality and productivity; while the basic seven tools are powerful for problem solving. However, to make them successful and effective tools for process and quality improvement, strong commitment from top management and an overwhelming desire for ever-improving quality (i.e. Kaizen philosophy) is a must.